clutch FORD FIESTA 2007 User Guide

206-00-28 Brake System - General Information 206-00-28
DIAGNOSIS AND TESTING
PINPOINT TEST L : SLOW OR INCOMPLETE BRAKE PEDAL RETURN
TEST CONDITIONS
DETAILSIRESU LTSIACTIONS /"'
I L1: CHECK FOR BRAKE PEDAL RETURN I[<.
Run the engine at fast idle while making several
brake applications. Pull the brake pedal rear-
ward with approximately 44.5 N
(1 0 lbs) force.
Release the brake pedal and measure the
distance to the floor pan. Make a hard brake
application. Release the brake pedal and
measure the brake pedal to floor pan distance.
The brake pedal should return to its original
position.
Did the brake pedal return to its original posi-
tion?
+ Yes
Vehicle OK.
+ No
GO to L2.
I L2: CHECK FOR BRAKE PEDAL BINDING
1 171 Check the brake pedal for free operation.
I Is the brake pedal operating freely?
+ Yes
I INSTALL a new brake booster. REFER to:
(206-07 Power Brake Actuation)
Brake Booster
- LHD (Removal and lnstallation),
Brake Booster
- RHD (Removal and lnstallation).
TEST the system for normal operation.
+ No
REPAIR or INSTALL new brake pedal bush-
ings. REFER to: (206-06 Hydraulic Brake
Actuation)
Brake Pedal
- LHD, Vehicles With: Manual
Transaxle (Removal and lnstallation),
Brake Pedal
- LHD, Vehicles With: 4-Speed
Automatic Transmission
(AW81-40), Vehicles
With: Automated Gearshift (Removal and
Installation),
Brake Pedal
- RHD (Removal and lnstallation).
TEST the system for normal operation.
Component Tests It is possible that all evidence of fluid leakage may
have washed off if the vehicle has been operated
in rain or snow, as brake fluid is water-soluble.
Hydraulic Leak Check Refill the system, bleed then apply the brakes
several times. Examine the system to verify that
NOTE:Thet-e is a common clutch and brake fluid
the reservoir fluid level is actually dropping. Locate
reservoir, therefore it is possible that a clutch leak
can lead to reduction in the reservoir level.
-- --
2006.0 Fiesta 1212006 G28494en
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206-00-33 Brake System - General Information 206-00-33
GENERAL PROCEDURES
Brake System Pressure Bleeding(l2 141 0)
Bleeding
i General Equipment Vehicles with anti-lock brakes
All vehicles
Worldwide Diagnostic System (WDS)
Brakelclutch system pressure bleederlfiller
A WARNING: Brake fluid contains polyglycol
ethers and polyglycols. Avoid contact with
the eyes. Wash hands thoroughly after
handling. If brake fluid contacts the eyes,
flush the eyes for
15 minutes with cold
running water. Get medical attention if
irritation persists. If taken internally, drink
water and induce vomiting. Get medical
attention immediately. Failure to follow
these instructions may result in personal
injury.
4. N0TE:This ste.p is only necessary when
changing the brake fluid to remove the used
A CAUTI0N:If brake fluid is spilt on the
paintwork, the affected area must be
immediately washed down with cold water.
/
brake fluid from the hydraulic control unit
I N0TE:Make sure that the vehicle is standing on a
level surface.
N0TE:The system consists of separate circuits for
each front and diagonally opposite rear wheel.
Each circuit can be bled independently.
I. Fill the brake fluid reservoir to the MAX mark.
2. CAUTIONS:
AMake sure that the pressure within the
brake system does not exceed
1 bar.
n~ake sure that the pressure bleeding
equipment is filled with new brake fluid to
the correct specification.
Using the
brakelclutch system pressure
bleederlfiller, pressure bleed the system in
accordance with the manufacturer's
instructions.
3n ACAUTION:M~~~ sure that the bleed nipple
cap is installed after bleeding the brake
line(s). This will prevent corrosion to the
bleed nipple. Failure to follow this instruction
I may result in the bleed nipple becoming
seized.
Fill the brake fluid reservoir to the
MAX mark
as necessary. (HCU).
Using
WDS, bleed the brake system.
2006.0 Fiesta 1212006
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206-0619 Hydraulic Brake Actuation 206-0619
REMOVAL AND INSTALLATION
Disconnect the brake tubes from the brake 11. Disconnect the low brake fluid warning
master cylinder. indicator switch electrical connector.
I
All vehicles
9m &AUTION:C~~ the clutch master cylinder
feed hose to prevent fluid loss or dirt
ingress.
Disconnect the clutch master cylinder feed
hose from the brake fluid reservoir.
12. Remove the brake master cylinder and
brake fluid reservoir assembly.
Installation
A CAUTI0N:Make sure the brake master
cylinder vacuum seal is correctly
positioned before installation.
I. To install, reverse the removal procedure.
2. Bleed the brake system. For additional
information, refer to Section
206-00 [Brake
System
- General Information].
10. Detach the brake master cylinder from the
brake booster.
2006.0 Fiesta 1212006 G89191 en
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303-0049 Engine System - General Information 303-00-49
GENERAL PROCEDURES
Flywheel lnspection - Vehicles With: Dual Mass Flywheel
1. lnspection details for the dual mass flywheel
are contained in the Diagnosis and Testing
procedure.For additional information, refer
to: (308-00 Manual
Transmission/Transaxle
and Clutch - General Information)
Manual Transmission and Clutch
- Vehicles
With: MT-75 (Diagnosis and Testing),
Manual Transaxle and Clutch
vehicles With:
VXT-75 (Diagnosis and Testing),
Manual Transmission and Clutch
- Vehicles
With: MT82 (Diagnosis and Testing).
2006.0 Fiesta 1212006 G272661 en
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Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
303-01 A-68 Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma) 303-01 A-68
IN-VEHICLE REPAIR
Crankshaft Rear Seal(21 468 4)
Discard the crankshaft rear oil seal carrier.
Removal
Special Tool(s) Discard the bolts.
Vehicles with manual transaxle
21168
21 540
1. Remove the clutch disc and pressure plate.
For additional information, refer to: Clutch
Disc and Pressure Plate (308-01 Clutch,
Removal and lnstallation).
2. Using the special tool, remove the flywheel.
Discard the bolts. Locking
Tool, Flywheel
303-393 (21 -1 68)
Gauge, Bolt Angle
303- 1 74 (2 1 -540)
Installation
All vehicles
4. Remove the crankshaft rear oil seal carrier.
All vehicles
1. Clean the crankshaft journal.
2. N0TE:lnstall a new crankshaft rear oil seal
carrier.
N0TE:A new crankshaft rear oil seal carrier is
supplied with an alignment sleeve which must be
removed following installation.
Vehicles with automatic transaxle N0TE:Do not lubricate the oil seal or crankshaft
3. Using the special tool, remove the flexplate. journal.
2006.0 Fiesta 1212006 GI 83743en
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Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
303-01 A-69 Duratec-1 6V (Sigma)/l .6L Duratec-I 6V
(Sigma)
303-01 A-69
IN-VEHICLE REPAIR
Install the crankshaft rear oil seal carrier. 4. Install the clutch disc and pressure plate.
For additional information, refer to: Clutch
Disc and Pressure Plate (308-01 Clutch,
Removal and Installation).
Vehicles with automatic transaxle
5. N0TE:Position of location stud for the
flexplate.
NOTE:
l nstall new flexplate retaining bolts.
Using the special tool, install the flexplate.
Tighten the bolts in the sequence shown in
two stages:
Vehicles with manual transaxle Stage 1: 30 Nm.
Stage 2: 80 degrees. - 3. N0TE:Position of location stud for the -
flywheel.
N0TE:lnstall new flywheel retaining bolts.
Using the special tool, install the flywheel.
Tighten the bolts in the sequence shown in
two stages:
Stage 1: 30
Nm.
Stage 2: 80 degrees.
1
6. Remove the special tool.
2006.0 Fiesta 1212006 GI 83743en
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Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
Duratec-I 6V (Sigma)/l .6L Duratec-16V (Sigma)
REMOVAL
33. Disconnect the NC compressor clutch 36. Disconnect the crankshaft position (CKP)
electrical connector. sensor
electrical connector.
34. Disconnect the NC high-pressure cut-off 37. Disconnect the reversing lamp switch
switch electrical connector. electrical connector.
35. Disconnect the oil pressure switch
electrical connector. 38. Disconnect the ignition switch to starter
motor solenoid and battery to starter motor
solenoid cables.
39m ACAUTION:~~~~ bending of the exhaust
flexible pipe may cause damage resulting
in failure.
2006.0 Fiesta IZIZOO~ G113163en
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Engine - 1.25L Duratec-I 6V (Sigma)llm4L
303-01A-79 Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma) 303-01 A-79
REMOVAL
56. Disconnect the gearshift actuator electrical Remove the spring clip.
, connector (colored gey).
59. Remove the gearshift cables cover.
57m ACAUTION:I brake fluid is spilt on the
paintwork, the affected area must be
immediately washed down with cold water.
Disconnect the clutch slave cylinder supply
line.
Remove the spring clip.
Vehicles without automated gearshift
58' ACAUTION:~ brake fluid is spilt on the
paintwork, the affected area must be
immediately washed down with cold water.
Disconnect the clutch slave cylinder supply
line.
60. Detach the gearshift cables from the
transaxle.
Detach the gearshift cables and the selector
cable from the selector levers.
Turn the abutment sleeve clockwise and
detach the cables from the bracket.
All vehicles
'Irn ~CAUTION:DO not support the engine
directly on the oil pan.
2006.0 Fiesta 12/2oo6 G113163en
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Engine - 1.25L Duratec-1 6V (Sigma)ll.4L
303-01 A-89 Duratec-1 6V (Sigma)ll.GL Duratec-1 6V (Sigma) 303-01 A-89
REMOVAL
44m ACAUTION:~~~~ bending of the exhaust Vehicles with air conditioning
I flexible pipe may cause damage resulting 47.
Disconnect the air conditioning (NC)
, in failure. low-pressure cutoff switch electrical
Support the exhaust
flexible pipe with a connector.
suitable support
wrap or suitable splint.
48. Disconnect the NC compressor clutch
45. Detach the exhaust flexible pipe from the electrical connector.
catalytic converter.
Discard the nuts and the gasket.
46. Remove the accessory drive belt.
For additional information, refer to:
Accessory Drive
Belt - I .4L Duratec-I 6V
(Sigma)ll .6L Duratec-1 6V (Sigma),
Vehicles With: Air Conditioning (303-05
Accessory Drive, Removal and
Installation)
I Accessory Drive Belt - I .4L Duratec-I 6V
(Sigma)ll .6L Duratec-1 6V (Sigma),
Vehicles Without: Air Conditioning
(303-05 Accessory Drive,
Removal and
Installation).
49. Disconnect the NC high-pressure cutoff
switch
electrical connector.
2006.0 Fiesta 1212006 G380458en
procarmanuals.com

Engine - 1.25L Duratec-1 6V (Sigma)llm4L
303-01 A-I 03 Duratec-1 6V (Sigma)/l .6L Duratec-1 6V (Sigma) 303-01A-I 03
DISASSEMBLY
43. Remove the oil pan retaining bolts. 46. Remove the oil pump.
Discard the gasket.
Discard the crankshaft front seal.
44m ACAUTION:~~ order to prevent damage
to the sealing surfaces, only use the
designated special tool to remove the oil
Vehicles with manual transaxle
PanmDonotuseachiselorscrewdriverfor 47. Removetheclutchdiscandpressureplate.
removal. For additional information, refer to: Clutch
N0TE:Tighten the lock nut against the oil pan and Disc and Pressure Plate (308-01 Clutch,
use several taps to release the oil pan from the Removal and Installation).
cylinder block. 48. Using the special tool, remove the flywheel.
Using the special tools, remove the oil pan.
Discard the bolts.
45. Remove the oil pump pickup pipe. Vehicles with automatic transaxle
Discard the gasket. 49. Using the special tool, remove the flexplate.
2006.0 Fiesta 1212006 GI 54224en
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